DESIGN AND FABRICATION OF

ELECTRO-MAGNETIC BRAKING SYSTEM

A Project report submitted in partial fulfilment of the requirement for the award of
the Degree

BACHELOR OF TECHNOLOGY

IN

MECHANICAL ENGINEERING

Submitted By

TUSHAR VERMA (301403720038)

NAIVEDYA SONI (301043720025)

NILESH SOLANKI (301403720061)

Under the Esteemed Guidance of

**********
Assistant Professor

DEPARTMENT OF MECHANICAL ENGINEERING

SHRI SHANKARACHARYA TECHNICAL CAMPUS, BHILAI (490020)
 LIST OF CONTENTS

CHAPTER-I : INTRODUCTION
1.1 Types of Brakes

1.1.1 On the Basis of Power Source

1.1.2 On the Basis of Frictional Braking Contact

1.1.3 On the Basis of Application

1.1.4 On the Basis of Brake Force Distribution

1.2 Principle of Braking System

1.3 Types of Braking System

1.4 Objectives

1.5 Significance and Scope

CHAPTER-II : LITERATURE SURVEY

CHAPTER-III : ELECTRO-MAGNETIC BRAKING SYSTEM

3.1 Background and History

3.2 Components of Electro-Magnetic Braking System

3.3 Construction of Electro-Magnetic Braking System

3.4 Working of Electro-Magnetic Braking System

3.5 Advantages

3.6 Dis-advantages

3.7 Applications
CHAPTER-IV : CALCULATIONS

4.1 Standard Calculations

4.2 Design Calculations

4.3 Braking Torque and Braking Time

CHAPTER-V : 3D MODEL DESIGN OF ELECTRO-

MAGNETIC BRAKING SYSTEM USING CATIA

5.1 Catia Introduction

5.2 Design Of Components Using Catia

5.2.1 Design of Bike Tire (or) Wheel

5.2.2 Design of Motor

5.2.3 Design of Frame

5.2.4 Design of Bearing

5.2.5 Assembly of the Components

CHAPTER-VI : RESULTS AND DISCUSSION

CHAPTER-VII : CONCLUSION

7.1 CONCLUSION
 CHAPTER-I

INTRODUCTION
 CHAPTER-1
INTRODUCTION

Brake Definition and Background

A brake is a mechanical device that inhibits motion by absorbing energy from

a moving system. It is used for slowing or stopping a moving vehicle, wheel, axle, or
to prevent its motion, most often accomplished by means of friction. Brakes may be
broadly described as using friction, pumping, or electromagnetic. One brake may use
several principles: for example, a pump may pass fluid through an orifice to create
friction

Most brakes commonly use friction between two surfaces pressed together to
convert the kinetic energy of the moving object into heat, though other methods of
energy conversion may be employed. For example, regenerative braking converts
much of the energy to electrical energy, which may be stored for later use. Other
methods convert kinetic energy into potential energy in such stored forms
as pressurized air or pressurized oil. Eddy current brakes use magnetic fields to
convert kinetic energy into electric current in the brake disc, fin, or rail, which is
converted into heat. Still other braking methods even transform kinetic energy into
different forms, for example by transferring the energy to a rotating flywheel.

Brakes are generally applied to rotating axles or wheels, but may also take
other forms such as the surface of a moving fluid (flaps deployed into water or air).
Some vehicles use a combination of braking mechanisms, such as drag racing cars
with both wheel brakes and a parachute, or airplanes with both wheel brakes and drag
flaps raised into the air during landing.

Since kinetic energy increases quadratically with velocity (KE=1/2 mv2), an

object moving at 10 m/s has 100 times as much energy as one of the same mass
moving at 1 m/s, and consequently the theoretical braking distance, when braking at
the traction limit, is 100 times as long. In practice, fast vehicles usually have
significant air drag, and energy lost to air drag rises quickly with speed.
 Almost all wheeled vehicles have a brake of some sort. Even baggage
carts and shopping carts may have them for use on a moving ramp. Most fixed-wing
aircraft are fitted with wheel brakes on the undercarriage. Some aircraft also
feature air brakes designed to reduce their speed in flight. Notable examples
include gliders and some World War II-era aircraft, primarily some fighter
aircraft and many dive bombers of the era. These allow the aircraft to maintain a safe
speed in a steep descent. The Saab B 17 dive bomber and Vought F4U Corsair fighter
used the deployed undercarriage as an air brake.

Friction brakes on automobiles store braking heat in the drum brake or disc
brake while braking then conduct it to the air gradually. When traveling downhill
some vehicles can use their engines to brake. When the brake pedal of a modern
vehicle with hydraulic brakes is pushed against the master cylinder, ultimately
a piston pushes the brake pad against the brake disc which slows the wheel down. On
the brake drum it is similar as the cylinder pushes the brake shoes against the drum
which also slows the wheel dow

1.1 Types of Brakes

 On the Basis of Power Source

The power source which carries the pedal force applied by the driver on
brake pedal to the final brake drum or brake disc in order to de accelerate
or stop the vehicle the braking systems are of 6 types-
1. Mechanical brakes
2. Hydraulic brakes
3. Air or pneumatic brakes
4. Vacuum brakes
5. Magnetic brakes
6. Electric brakes

 On the Basis of Frictional Braking Contact

On the basis of the final friction contact made between the rotating brake
components i.e. brake drum or disc rotor and the brake shoe the braking
systems are of 2 types-
 1. Internal expanding brakes (e.g.- drum brakes)
2. External contracting brakes(e.g. disc brakes)

 On the Basis of Application-

On the basis of method of applying brakes, braking systems are of 2 types-
1. Foot or service brakes
2. Hand or parking brakes

 On the Basis of Brake Force Distribution

1. Single acting brakes
2. Dual acting brakes

1.1.1. On the Basis of Power Source

1. Mechanical Brakes

It is the type of braking system in which the brake force applied by the
driver on the brake pedal is transferred to the final brake drum or disc rotor
through the various mechanical linkages like cylindrical rods, fulcrums,
springs etc. In order to de accelerate or stop the vehicle.

Mechanical brakes were used in various old automobile vehicles but

they are obsolete now days due to their less effectiveness.
2. Hydraulic Brakes

It is the type of braking system in which the brake force applied by the
driver on brake pedal is first converted into hydraulic pressure by Master
Cylinder (for reference read article on master cylinder) than this hydraulic
pressure from master cylinder is transferred to the final brake drum or disc
rotor through brake lines.

Instead of mechanical linkages, brake fluid is used in hydraulic brakes

for the transmission of brake pedal force in order to stop or de accelerates the
vehicle.

Almost all the bikes and cars on the road today are equipped with the
hydraulic braking system due to it high effectiveness and high brake force
generating capability.

3. Air or Pneumatic Brakes

It is the types of braking system in which atmospheric air through

compressors and valves is used to transmit brake pedal force from brake pedal
to the final drum or disc rotor.
 Air brakes are mainly used in heavy vehicles like busses and trucks
because hydraulic brakes fails to transmit high brake force through greater
distance and also pneumatic brakes generates higher brake force than
hydraulic brake which is the need of the heavy vehicle.

The chances of brake failure is less in case of pneumatic brakes as they

are usually equipped with a reserve air tank which comes in action when there
is a brake failure due to leakage in brake lines.

High end cars these days are using air brakes system due to its
effectiveness and fail proof ability.

4. Vacuum Brakes

It is the conventional type of braking system in which vacuum inside

the brake lines cause are brake pads to move which in turn finally stops or de
accelerate the vehicle.

Exhauster, main cylinder, brake lines, valves along with disc rotor or
drum are the main components that combines together to make a vacuum
braking system

Vacuum brakes were used in old or conventional trains and are

replaced with air brakes now days because of its less effectiveness and slow
braking.
 Vacuum brakes are cheaper than air brakes but are less safe than air
brakes.

5. Magnetic Brakes.

In this types of braking system, the magnetic field generated by

permanent magnets is used to cause the braking of the vehicle.
 It works on the principle that when we pass a magnet through a
cooper tube, eddy current is generated and the magnetic field generated
by this eddy current provide magnetic braking.
 This is the friction less braking system thus there is less or no
wear and tear.
 This is the advanced technology in which no pressure is needed
to cause braking.
 The response to the braking in this is quite quick as compared
to other braking systems.
6. Electrical Brakes.

It is type of braking used in electric vehicle in which braking is

produced using the electrical motors which is the main source of power in
electric vehicles, it is further divided into 3 types-

(i) Plugging Brakes. When the brake pedal is pressed in the

electric vehicle equipped with plugging braking, the polarity of the
motors changes which in turn reverses the direction of the motor and
causes the braking.

(ii) Regenerative Braking. It is the type of electrical braking in

which at the time of braking the motor which is the main power source
of the vehicle becomes the generator i.e. when brakes are applied, the
power supply to the motor cuts off due to which the mechanical energy
from the wheels becomes the rotating force for the motor which in turn
converts this mechanical energy into the electric energy which is
further stored in the battery.

 Regenerative braking saves the energy and are widely

used in today’s electric vehicles.
 Tesla Model-S provides the most effective regenerative
braking

(iii) Dynamic or Rheostat Braking. It is the type of electrical

braking in which resistance provided by the rheostat causes the actual
braking, in this type a rheostat is attached to the circuit that provides
the resistance to the motor which is responsible for de acceleration or
stopping of the vehicle.
1.1.2 On Frictional Contact Basis

1. Drum Brakes or Internal Expanding Brakes

 It is the type of brake system in which a drum which is the
housing of the brake shoes along with actuation mechanism is attached
with the wheel hub in such a fashion that the outer part of the drum
rotates with the wheel and inner part remains constant.

 When brakes are applied the actuating mechanism (wheel

cylinder or mechanical linkage.) causes the brake shoes to expand due
to which the outer frictional surface of the brake shoes makes frictional
contact with the rotating drum part which in turn stops or de accelerate
the vehicle.
 2. Disc Brake or External Contracting Brakes.

It is the types of braking system in which instead of a drum assembly a

disc rotor attached to the hub of the wheel in such a fashion that it rotates with
the wheel, this disc rotor is clamped in between the caliper which is rigidly
fixed with the knuckle or upright of the vehicle.

 This caliper used is the housing of the brake shoes along with the
actuation mechanism (mechanical linkages or caliper cylinder).

 When the brakes are applied the actuation mechanism contracts the
attached brake shoes which in turn makes the frictional contact with the
rotating disc rotor and causes the braking of the vehicle

1.1.3 On Application Basis

1. Service Brake or Foot Brakes

It is the type of brakes in which the brakes are applied when the driver
presses the brake pedal mounted inside the cockpit or at the foot space of the
vehicle with his foot, this pedal force applied by the driver is further
multiplied and sent to the braking drum or disc either by mechanical linkages
or by hydraulic pressure which in turn causes braking.
 In cars foot operated brakes are used and in bikes the
combination of foot and hand operated brakes are used.
 2. Hand Brake or Parking Brake
This type of brakes are also known as emergency brake as they are
independent of the main service brake, hand brakes consists of a hand
operated brake lever which is connected to the brake drum or disc rotor
through the metallic cable.
 When hand brake lever is pulled, tension is created in the
metallic rod which in turn actuates the brake drum or disc rotor
mechanism and final braking occurs.
 Hand brakes are usually used for stable parking of the vehicle
either on flat road or slope that is why it is also called parking brakes.

1.1.4 On Brake Force Distribution Basis

1. Single Acting Brakes

It is the type of braking in which brake force is transferred to either a
pair of wheels(in cars) or to the single wheel(in bikes) through single actuation
mechanism(mechanical linkages or master cylinder).
 These types of braking system are commonly used in bikes or
in light purpose vehicles.
2. Dual Acting Brakes
It is the type of braking in which the brake force is transferred
to all the wheels of the vehicle through dual actuation mechanism
(tandem master cylinder or mechanical linkages).
 This type of braking is used in cars as well as in heavy purpose
vehicle.

1.1.1 Principle of Braking System

The principle of braking in road vehicles involves the conversion of

kinetic energy into thermal energy (heat). When stepping on the brakes, the
driver commands a stopping force several times as powerful as the force that
puts the car in motion and dissipates the associated kinetic energy as heat.
Brakes must be able to arrest the speed of a vehicle in short periods of time
 regardless how fast the speed is. As a result, the brakes are required to have
the ability to generating high torque and absorbing energy at extremely high
rates for short periods of time.

1.1.2 Types of Braking System

Electromagnetic Brake System

A rising style of brake system, electromagnetic brakes use an electric
motor that is included in the automobile which help the vehicle come to a stop.
These types of brakes are in most hybrid vehicles and use an electric motor to
charge the batteries and regenerative brakes. On occasion, some buses will use
it as a secondary retarder brake.

Frictional Brake System

A frictional brake system is found in many automobiles. They are
service brakes, and typically found in two forms; pads and shoes. As the name
implies, these brakes use friction to stop the automobile from moving. They
typically include a rotating device with a stationary pad and a rotating weather
surface. On most band brakes the shoe will constrict and rub against the
outside of the rotating drum, alternatively on a drum brake, a rotating drum
with shoes will expand and rub against the inside of the drum.

Hydraulic Brake System

A hydraulic brake system is composed of a master cylinder that is fed
by a reservoir of hydraulic braking fluid. This is connected by an assortment
of metal pipes and rubber fittings which are attached to the cylinders of the
wheels. The wheels contain two opposite pistons which are located on the
band or drum brakes which pressure to push the pistons apart forcing the brake
pads into the cylinders, thus causing the wheel to stop moving.
1.1.3 Objective

Primary Objective
The main objective of our project is to design and fabricate an
Electromagnetic Braking System model.

Secondary Objective
 Besides the main objective, following are our secondary objectives:
 To understand project planning and execution
 To understand the fabrication techniques in a mechanical workshop
 To understand the usage of various mechanical machine tools and
also measuring tools
 To make day to day human life more easier by proper use of
technology

1.1.4 Significance and Scope

 Electromagnetic brakes satisfy all the energy requirements of braking

without the use of friction. They have better heat dissipation capability to
avoid problems that friction brakes faces times.
 They can also be used as supplementary retardation equipment in
addition to the regular friction brakes on heavy vehicles.
 These brakes’s component cost is less so these brakes are cheap.
 They can be used as an alternative method for the future crisis of the
crude oils.
 Chapter-3
ELECTRO-MAGNETIC BRAKING SYSTEM
 Chapter -3
Electro-magnetic braking system

3.1 Background and Rational

Electromagnetic brakes (also called electro-mechanical brakes or EM brakes)

slow or stop motion using electromagnetic force to apply mechanical resistance
(friction). The original name was "electro-mechanical brakes" but over the years the
name changed to "electromagnetic brakes", referring to their actuation method. Since
becoming popular in the mid-20th century especially in trains and trams, the variety
of applications and brake designs has increased dramatically, but the basic operation
remains the same. Electromagnetic brakes are the brakes working on the electric
power & magnetic power. They work on the principle of electromagnetism. These
brakes are an excellent replacement on the convectional brakes due to their many
advantages. The reason for implementing this brake in automobiles is to reduce wear
in brakes as it frictionless. Electromagnetic brakes are of today’s automobiles. The
working principle of this system is based on faradays first law of electromagnetic
induction i.e when a magnetic flux linking with a conductor changes an emf is
induced in the coil. An additional current is supplied to the coils so that it creates an
opposing torque. This results in the rotating wheel or rotor comes to rest/ neutral.

History

It is found that electromagnetic brakes can develop a negative power which

represents nearly twice the maximum power output of a typical engine, and at least
three times the braking power of an exhaust brake. (Reverdin 1994). This
performance of electromagnetic brakes make them much more competitive candidate
for alternative retardation equipments compared with other retarders. By using by
using the electromagnetic brakes are supplementary retardation equipment, the
friction brakes can be used less frequently and therefore practically never reach high
temperatures. The brake linings would last considerably longer before requiring
maintenance and the potentially “brake fade” problem could be avoided. In research
conducted by a truck manufacturer, it was proved that the electromagnetic brake
assumed 80% of the duty which would otherwise have been demanded of the regular
service brake (Reverdin 1974). Furthermore the electromagnetic brakes prevent the
danger that can arise from the prolonged use of brake beyond their capability to
dissipate heat. This is most likely to occur while a vehicle descending a long gradient
at high speed. Ina study with a vehicle with 5 axles and weighting 40 tones powered
by a powered by an engine of 310 b.h.p travelling down a gradient of 6% at a steady
speed between 35 and 40 m.h.p, it can be calculated that the braking power necessary
to maintain this speed ot the order of 450 hp. The brakes, therefore, would have to
absorb 300 hp, meaning that each brake in the 5 axels must absorb 30 hp, that a
friction brake can normally absorb with self destruction. The magnetic brake is wall
suited to such conditions since it will independently absorb more than 300 hp
(Reverdin 1974). It therefore can exceed the requirements of continuous uninterrupted
braking, leaving the friction brakes cool and ready for emergency braking in total
safety. The installation of an electromagnetic brake is not very difficult if there is
enough space between the gearbox and the rear axle. If did not need a subsidiary
cooling system. It relay on the efficiency of engine components for its use, so do
exhaust and hydrokinetic brakes. The exhaust brake is an on/off device and
hydrokinetic brakes have very complex control system. The electromagnetic brake
control system is an electric switching system which gives it superior controllability.

3.2 Components of Electro-Magnetic Braking System

The electro-magnetic braking system consists of mainly the following parts. They
are:-
 Base frame
 Shaft
 Belt and Pulleys
 Dc- motor
 Braking unit
 Tire(or) wheel
 Bearings
 Adapter
3.2.1 Base Frame.
The components require support during the operation. The base frame
facilitates necessary support for this purpose.

3.2.2 Shaft

A shaft is a rotating machine element, usually circular in cross section, which

is used to transmit power from one part to another, or from a machine which produces
power to a machine which absorbs power. The various members such
as pulleys and gears are mounted on it.
One end of the shaft is connected to motor with the help of pulley and belts and the
other end is connected to wheel so that it helps in transmitting motion from motor to
wheel

Types
They are mainly classified into two types.
 Transmission shafts are used to transmit power between the source and the
machine absorbing power; e.g. counter shafts and line shafts.
 Machine shafts are the integral part of the machine itself; e.g. crankshaft.

Materials
 The material used for ordinary shafts is mild steel. When high strength is
required, an alloy steel such as nickel, nickel-chromium or chromium-vanadium
steel is used.
 Shafts are generally formed by hot rolling and finished to size by cold
drawing or turning and grinding.
Standard sizes
Machine shafts
 Up to 25 mm steps of 0.5 mm
Transmission shafts
 25 mm to 60 mm with 5 mm steps
 60 mm to 110 mm with 10 mm steps
 110 mm to 140 mm with 15 mm steps
 140 mm to 500 mm with 20 mm steps
The standard lengths of the shafts are 5 m, 6 m and 7 m
Stresses
The following stresses are induced in the shafts.
1. Shear stresses due to the transmission of torque (due to torsional load).
2. Bending stresses (tensile or compressive) due to the forces acting upon the
machine elements like gears and pulleys as well as the self weight of the shaft.
3. Stresses due to combined torsional and bending loads.

3.2.3 Belt and Pulleys

A pulley is a wheel on an axle or shaft that is designed to support

movement and change of direction of a taut cable or belt, or transfer of power
between the shaft and cable or belt.
 A belt and pulley system is characterized by two or more pulleys in
common to a belt. This allows for mechanical power, torque, and speed to be
transmitted across axles. If the pulleys are of differing diameters are used
different speeds can be obtained

3.2.4 DC-Motor:

A DC motor is any of a class of rotary electrical machines that converts direct

current electrical energy into mechanical energy. The most common types rely on the
forces produced by magnetic fields. Nearly all types of DC motors have some internal
mechanism, either electromechanical or electronic; to periodically change the
direction of current flow in part of the motor.
 DC motors were the first type widely used, since they could be powered from
existing direct-current lighting power distribution systems. A DC motor's speed can
be controlled over a wide range, using either a variable supply voltage or by changing
the strength of current in its field windings. Small DC motors are used in tools, toys,
and appliances. The universal motor can operate on direct current but is a
lightweight brushed motor used for portable power tools and appliances. Larger DC
motors are used in propulsion of electric vehicles, elevator and hoists, or in drives for
steel rolling mills. The advent of power electronics has made replacement of DC
motors with AC motors possible in many applications.

Power ratings are 160-24 volts, maximum current is 2.0A and the speed is 0-
1425 rpm.

3.2.5 Braking Unit

The braking unit consists of a permanent magnet and a stator which has 3
spokes made of iron having copper wires windings.

The stator may consist of 2 to 18 spokes depending upon the application. The
copper wires may be of different gauges. On increasing the no.of turns of copper
windings the braking effect can be increased due to passage of more current through
the coils.
3.2.6 Tire (or) Wheel

A wheel is a circular block of a hard and durable material at whose center has
been bored a circular hole through which is placed an axle bearing about which the
wheel rotates when a moment is applied by gravity or torque to the wheel about its
axis, thereby making together one of the six simple machines.

3.2.7 Bearings

A bearing is a machine element that constrains relative motion to only the

desired motion, and reduces friction between moving parts. The design of the bearing
may, for example, provide for free linear movement of the moving part or for
free rotation around a fixed axis; or, it may prevent a motion by controlling
the vectors of normal forces that bear on the moving parts. Most bearings facilitate the
desired motion by minimizing friction. Bearings are classified broadly according to
the type of operation, the motions allowed, or to the directions of the loads (forces)
applied to the parts.

Rotary bearings hold rotating components such as shafts or axles within

mechanical systems, and transfer axial and radial loads from the source of the load to
the structure supporting it. The simplest form of bearing, the plain bearing, consists of
a shaft rotating in a hole. Lubrication is often used to reduce friction. In the ball
bearing and roller bearing, to prevent sliding friction, rolling elements such as rollers
or balls with a circular cross-section are located between the races or journals of the
bearing assembly. A wide variety of bearing designs exists to allow the demands of
the application to be correctly met for maximum efficiency, reliability, durability and
performance.
 The purpose of Bearing is to reduce rotational friction and support radial and
axial loads

Types of bearings

There are at least 6 common types of bearing, each of which operates on

different principles:-

 Plain bearing, consisting of a shaft rotating in a hole. There are several specific
styles: bushing, journal bearing, sleeve bearing, rifle bearing, and composite bearing.

 Rolling-element bearing, in which rolling elements placed between the turning

and stationary races prevent sliding friction. There are two main types

 Ball bearing, in which the rolling elements are spherical balls

 Roller bearing, in which the rolling elements are cylindrical, taper and
spherical rollers

 Jewel bearing, a plain bearing in which one of the bearing surfaces is made of
an ultra hard glassy jewel material such as sapphire to reduce friction and wear

 Fluid bearing, a noncontact bearing in which the load is supported by a gas or

liquid,

 Magnetic bearing, in which the load is supported by a magnetic field

 Flexure bearing, in which the motion is supported by a load element which bends.
3.2.7 Adapter.

An (electrical) adapter is a device that converts attributes of one electrical

device or system to those of an otherwise incompatible device or system. Some
modify power or signal attributes, while others merely adapt the physical form of
one electrical connector to another.
Power ratings are 12 volts and maximum current 10A.
3.3 Construction of Electro-Magnetic Braking System:

The motor is placed on the bottom of the frame and the motion transmission
from motor to shaft is done with the help of pulleys and belt i.e one end of the shaft is
connected to a pulley and the shaft pulley is connected is to the motor pulley with the
help of belt so that when motor pulley rotates due to the power supply the shaft pulley
rotates and the shaft pulley rotates and the shaft rotates which is mounted on the
frame with the help of bearings. Here the other end of the shaft is connected to one
side of the wheel so that when shaft rotates wheel also rotates. The braking unit
consists of permanent magnet, stator which has 3 spokes of iron winded with copper
wires. The permanent magnet is attached to the other side of the wheel and the stator
outer frame is welded to the base frame.

3.4 Working of Electro-Magnetic Braking System: There are two methods of

operations of the braking system.

(i) Braking system with EMF generation effect.

In this type an alternator of bikes is used as an braking unit. The braking unit
consists of permanent magnet and stator which has three spokes of iron material
winded with copper wires or magnetic wires. The permanent magnet and stator are
connected to the equipment as mentioned in the construction above.

When magnet which is attached to the wheel rotates an EMF is generated in

the coils according to Faraday’s Law of Electromagnetic Induction, This generated
EMF can be used to charge batteries with the help of rectifier and regulator because
the output EMF is in AC form. So this process of generating EMF when wheel is
freely rotating is known as EMF generating effect. In order to apply brakes a reverse
current is supplied from the adaptor which should be more than the produced EMF so
that the electro magnetic poles gets interchanged and creates an opposing torque to
the rotating wheel and tries to stop the wheel.

But in this method of operation the EMF generated is more than the reverse
current which we are supplying from adaptor. So the brakes are not making the wheel
stop. To avoid this either we have to increase the adaptor specifications (current and
voltage) or to stop the EMF generating effect. If we change the adaptor specifications
i.e. increasing current and voltage the coils in the electromagnet gets damaged due to
coils gauge and less no. of turns. So we have done this experiment in second method
of operation which is to eliminate EMF generating effect is as follows.

(ii) Braking system without EMF generation.

The construction details are same as the first method. But only difference is
the magnetic replaced by circular steel plate in the braking unit. So when
electromagnet is energized by supplying current from adaptor it creates a magnetic
field which attracts the rotating circular steel plate creating an opposing torque to stop
the rotation of the wheel. In this there is a gap of 2mm between the steel plate and
electromagnet so this is frictionless braking system which is major advantage. As the
rotating circular plate does not produce any EMF, so the brakes are applied without
any EMF generation.

So we used 2nd method of operation to apply brakes in order to overcome the

difficulties obtained in the first method.
3.4 Advantages of Electro-Magnetic Braking System

 We can use these brakes to charge batteries with the help of rectifiers
and regulators
 Problems of drum distortion at widely varying temperatures.
 Which is common for friction-brake drums to exceed 500 °C
 surface temperatures when subject to heavy braking
 demands, and at temperatures of this order, a reduction in the
coefficient of friction (“brake fade‟) suddenly occurs
 This is reduced significantly in electromagnetic disk brake systems.
 Potential hazard of tire deterioration and bursts due to friction is
eliminated.
 There is no need to change brake oils regularly.
 There is no oil leakage
 The electromagnetic brakes have excellent heat dissipation efficiency
owing to the high temperature of the surface of the disc which is being cooled.
 Due to its special mounting location and heat dissipation mechanism,
electromagnetic brakes have better thermal dynamic performance than regular
friction brakes.
  Burnishing is the wearing or mating of opposing surfaces .This is
reduced significantly here. 11)
 In the future, there may be shortage of crude oil; hence by-products
such as brake oils will be in much demand. EMBs will overcome this problem.
 Electromagnetic brake systems will reduce maintenance cost.
 The problem of brake fluid vaporization and freezing iseliminated.
 Electric actuation, no fluid.
 Easy individual wheel braking control

3.5 Disadvantages of Electro-Magnetic Braking System

 Failure to act as a holding device

 Usage of electric power for braking
 Less effective under very low velocities..
 It cannot use grease or oil.
 Dependence on battery power to energize the brake system drains
down the battery much faster.
 Due to residual magnetism present in electromagnets, thebrake shoe
takes time to come back to its original position.
 The installation of an electromagnetic brake is very difficult if there is
not enough space between the gearbox and the rear axle.

3.6 Applications

 Already in use under some railway system

 Can be used for any road vehicles
 Equally applicable to heavy and light vehicles
 Can be used as additional retarder for aircrafts
 May also find application in virtually any rotating system which have
metallic parts
 This brake system can be use in two wheeler.
 Electromagnetic braking system can be used as a modern technology
of braking in automobile.
 Electromagnetic braking system will be used in all types of light motor
vehicle like car and heavy motor vehicle.
 Chapter-5
3D MODEL DESIGN OF ELECTRO-MAGNETIC
BRAKING SYSTEM USING CATIA
 Chapter-5
3D MODEL DESIGN OF ELECTRO-MAGNETIC BRAKING
SYSTEM USING CATIA

5.1. Catia Introduction.

CATIA, (an acronym of computer-aided three-dimensional interactive

application) is a multi-platform software suite for Computer-Aided
Design (CAD), Computer-Aided Manufacturing (CAM), Computer-Aided
Engineering (CAE), PLM and 3D, developed by the French company Dassault
Systems.

Scope of Application

Commonly referred to as a 3D Product Lifecycle Management software suite,

CATIA supports multiple stages of product development, including conceptualization,
design (CAD), engineering (CAE) and manufacturing (CAM). CATIA facilitates
collaborative engineering across disciplines around its 3DEXPERIENCE platform,
including surfacing & shape design, electrical, fluid and electronic systems
design, mechanical engineering and systems engineering.

CATIA facilitates the design of electronic, electrical, and distributed systems

such as fluid and HVAC systems, all the way to the production of documentation for
manufacturing.

Mechanical Engineering

CATIA enables the creation of 3D parts, from 2D sketches, sheet

metal, composites, molded, forged or tooling parts up to the definition of mechanical
assemblies. The software provides advanced technologies for mechanical surfacing
& BIW. It provides tools to complete product definition, including functional
tolerances as well as kinematics definition. CATIA provides a wide range of
applications for tooling design, for both generic tooling and mold & die. In the case of
Aerospace engineering an additional module named the aerospace sheet metal design
offers the user combine the capabilities of generative sheet metal design and
generative surface design.

Design

CATIA offers a solution to shape design, styling, surfacing workflow and

visualization to create, modify and validate complex innovative shapes from industrial
design to Class-A surfacing with the ICEM surfacing technologies. CATIA supports
multiple stages of product design whether started from scratch or from 2D sketches
(blueprints)

GEOMETRY FORMATION

CATIA is one of the world’s leading high-end CAD/CAM/CAE software

packages. CATIA (computer aided three dimensional interactive application) is a
multi-platform PLM/CAD/CAM/CAE commercial software suite developed by
Dassault systems and marketed worldwide by IBM. CATIA is written in the C++
programming language. CATIA provides open development architecture through the
use of interfaces, which can be used to customize or develop applications. The
applications in programming interfaces supported visual basic and C++ programming
languages.

Commonly referred to as 3D product lifecycle management (PLM) software

suite, CATIA supports multiple stages of product development. The stages range from
conceptualization, through design (CAD) and manufacturing (CAM), until analysis
(CAE). Each work bench of catiaV5 refers and each stage of product development for
different products. CATIA V5 features a parametric solid/surface-based package
which uses NURBS as the core surface representation and has several work benches
but provide KBE (knowledge based engineering) support.

The Sketcher Workbench

The Sketcher workbench is a set of tools that helps you create and constrain 2D
geometries. Features (pads, pockets, shafts, etc...) may then be created solids or
 modifications to solids using these 2D profiles. You can access the Sketcher
workbench in various ways. Two simple ways are by using the top pull down menu
(Start – Mechanical Design – Sketcher), or by selecting the Sketcher icon
. When you enter the sketcher, CATIA requires that you choose a plane to sketch on.
You can choose this plane either before or after you select the Sketcher icon. To exit

the sketcher, select the Exit Workbench ico n . The Sketcher Work bench
contains the following standards work bench specific

Tool Bars

 Profile Toolbar. The commands located in

toolbar allow you to create simple geometries
(rectangle, circle, line, etc.,) and more
complex geometries (profile, spline, etc.,)

 Operation Toolbar: Once a profile has been created, it

can be modified using commands such as trim, mirror,
chamfer, and other commands located in the
Operation toolbar.

 Constraint Toolbar: Profiles may be constrained with

dimensional (distances, angles, etc...) or geometrical
(tangent, parallel, etc...) constraints using the
commands located in the Constraint toolbar.

 Sketch Tools Toolbar: The commands in this

toolbar allow you to work in different modes which
make sketching easier.

 User Selection Filter Toolbar: Allows you to

activate different selection filters.
Profile Toolbar

The Profile toolbar

contains 2D geometry
commands. These
geometries range from the
very simple (point,
rectangle, etc...) to the
very complex (splines,
conics, etc...). The Profile
toolbar contains many sub-toolbars. Most of these sub- toolbars contain different
options for creating the same geometry. For example, you can create a simple line, a
line defined by two tangent points, or a line that is perpendicular to a surface.
Reading from left to right, the Profile toolbar contain the following commands.

Profile Toolbar

 Profile: This command allows you to create a continuous set of lines and arcs
connected together.
 Rectangle / Predefined Profile toolbar: The default top command is rectangle.
Stacked underneath are several different commands used to create predefined
geometries.
 Circle / Circle toolbar: The default top command is circle. Stacked underneath
are several different options for creating circles and arcs.
 Spline / Spline toolbar: The default top command is spline which is a curved line
created by connecting a series of points.
 Ellipse / Conic toolbar: The default top command is ellipse. Stacked underneath
are commands to create different conic shapes such as a hyperbola.
 Line / Line toolbar: The default top command is line. Stacked underneath are
several different options for creating lines.
 Axis: An axis is used in conjunction with commands like mirror and shaft
(revolve). It defines symmetry. It is a construction element so it does not become
a physical part of your feature.

 Point / Point Toolbar: The default top command is point. Stacked underneath are
several different options for creating points.

Predefined Profile Toolbar

Predefined profiles are frequently used geometries. CATIA makes these profiles
available for easy creation which speeds up drawing time. Reading from left to right,
the Predefined Profile toolbar contains the following commands.

 Rectangle: The rectangle is defined

by two corner points. The sides of the
rectangle are always horizontal and
vertical.
 Oriented Rectangle: The oriented rectangle is defined by three corner points.
This allows you to create a rectangle whose sides are at an angle to the
horizontal.
 Parallelogram: The parallelogram is defined by three corner points.
 Elongated Hole: The elongated hole or slot is defined by two points and a radius.
 Cylindrical Elongated Hole: The cylindrical elongated hole is defined by a
cylindrical radius, two point and a hole radius.
 Keyhole Profile: The keyhole profile is defined by two center points and two
radii.
 Hexagon: The hexagon is defined by a center point and the radius of an inscribed
circle.
 Centered Rectangle: The centered rectangle is defined by a center point and a
corner point.
 Centered Parallelogram: The centered parallelogram is defined by a center point
(defined by two intersecting lines) and a corner point.
Circle Toolbar

The Circle toolbar contains several different ways

of creating circles and arcs. Reading from left to
right, the Circle toolbar contains the following
commands.

 Circle: A circle is defined by a center point and a radius.

 Three Point Circle: The three point circle command allows you to create a circle
using three circumferential points.
 Circle Using Coordinates: The circle using coordinates command allows you to
create a circle by entering the coordinates for the center point and radius in a
Circle Definition window.
 Tri-Tangent Circle: The tri-tangent circle command allows you to create a circle
whose circumference is tangent to three chosen lines.
 Three Point Arc: The three point arc command allows you to create an arc
defined by three circumferential points.
 Three Point Arc Starting with Limits: The three point arc starting with limits
allows you to create an arc using a start, end, and midpoint.
 Arc: The arc command allows you to create an arc defined by a center point, and
a circumferential start and end point.

Spline Toolbar

Reading from left to right, the Spline toolbar contains the following commands.

 Spline: A spline is a curved profile defined by three or more points.

The tangency and curvature radius at each point may be specified.
 Connect: The connect command connects two points or profiles
with a spline.Conic Toolbar
Reading from left to right, the Conic toolbar contains the
following commands.

 Ellipse: The ellipse is defined by center point and a major and minor axis points.
 Parabola by Focus: The parabola is defined by a focus, apex and a start and end
point.
 Hyperbola by Focus: The hyperbola is defined by a focus, center point, apex and
a start and end point.
 Conic: There are several different methods that can be used to create conic
curves. These methods give you a lot of flexibility when creating above three
types of curves.

Line Toolbar

The Line toolbar contains several different ways of creating

lines. Reading from left to right, the Line toolbar contains
the following commands.

 Line: A line is defined by two points.

 Infinite Line: Creates infinite lines that are horizontal, vertical or defined by two
points.
 Bi-Tangent Line: Creates a line whose endpoints are tangent to two other
elements.
 Bisecting Line: Creates an infinite line that bisects the angle created by two
other lines.

Point Toolbar

 The Point toolbar contains several different ways of

creating points. Reading from left to right, the Point
toolbar contains the following commands.
 Point by Clicking: Creates a point by clicking the left mouse button.
 Point by using Coordinates: Creates a point at a specified coordinate point.
  Equidistant Points: Creates equidistant points along a predefined path curve.
 Intersection Point: Creates a point at the intersection of two different elements.
 Projection Point: Projects a point of one element onto another.

Constraint Toolbar

Constraints can either be dimensional or geometrical. Dimensional constraints are

used to constrain the length of an element, the radius
or diameter of an arc or circle, and the distance or
angle between elements. Geometrical constraints are
used to constrain the orientation of one element
relative to another. For example, two elements may be
constrained to be perpendicular to each other. Other
common geometrical constraints include parallel, tangent, coincident, concentric,
etc... Reading from left to right:

 Constraints Defined in Dialoged Box: Creates geometrical and dimensional

constraints between two elements.
 Constraint: Creates dimensional constraints.
 Contact Constraint: Creates a contact constraint between two elements.
 Fix Together: The fix together command groups individual entities together.
 Auto Constraint: Automatically creates dimensional constraints.
 Animate Constraint: Animates a dimensional constraint between to limits.
 Edit Multi-Constraint: This command allows you to edit all your sketch
constraints in a single window.

 Visualization Toolbar: Allows you to,

among other things to cut the part by the
sketch plane and choose lighting effects and
other factors that influence how the part is
visualized.
 Tools Toolbar, Allows you to, mono go the other things to analyze a sketch for
problems , and create a datum
The Sketch Tools Toolbar

The Sketch tools toolbar contains icons that activate and deactivate different work
modes. These work modes assist you in drawing 2D profiles. Reading from left to
right, the toolbar contains the following work modes; (Each work mode is active if
the icon is orange and inactive if it is blue.)

 Grid: This command turns the sketcher grid on

and off.
 Snap to Point: If active, your cursor will snap to the
intersections of the grid lines.
 Construction / Standard Elements: You can draw two different types of elements
in CATIA a standard element and a construction element. A standard element
(solid line type) will be created when the icon is inactive (blue). It will be used to
create a feature in the Part Design workbench. A construction element (dashed
line type) will be created when the icon is active (orange). They are used to help
construct your sketch, but will not be used to create features.
 Geometric Constraints: When active, geometric constraints will automatically be
applied such as tangencies, coincidences, parallelisms, etc...

Dimensional Constraints: When active, dimensional constraints will automatically

be applied when corners (fillets) or chamfers are created, or when quantities are
entered in the value field. The value field is a place where dimensions such as line
length and angle are manually entered

5.2. 3D DESIGN OF ELECTRO MAGNETIC BRAKING SYSTEM

3D COMPONETNS ARE

1. TYRE
2. MOTOR
3. BASE FRAME
4. BEARING
5.2.1. DESIGN OF TYRE

STEP-1: DRAW THE PROFILE OF THE RIM USING SPLINE COMMAND,

CIRCLE COMMAND FROM PROFILE TOOL BAR AS SHOWN IN THE FIGURE

STEP-2: BY USING SHAFT COMMAND WE HAVE EXTRUDED THE

ABOVE PROFILE 3600 MENTIONED IN THE STEP-1 AS SHOWN IN
THEFIGURE
STEP-3: DRAW THE PROFILE OF TYRE USING SPLINE AND CIRCLE
COMMAND FROM PROFILE TOOL BAR AS SHOWN IN FIGURE

STEP-5: DRAW THE SPOKES OF THE TYRE USING SPLINE COMMAND

FROM THE CENTRE OF THE TYRE AND USING CIRCULAR PATTERN
COMMAND OBTAIN THE REQUIRED SPOKES ARE AS SHOWN IN THE
FIGURE
STEP-6: SELECTION OF MATERIAL OF RIM AND COLOUR OF TYRE
5.2.2. DESIGN OF MOTOR

STEP-1: DRAW THE MOTOR BY CREATING MOTOR FRONT,BACK

PART,STAND AND CENTRAL FRAME USING PROFLE TOOL BAR AND
APPLY REQUIRED DIMENSIONS USING CONSTRAINT TOOL BAR

STEP-2: USE COINCIDE COMMAND TO COINCIDE THE AXIS OF

MOTOR FRONT, BACK AND CENTRAL PART.

STEP-3: USE OFFSET OR CONTACT COMMAND TO ASSEMBLE

MOTOR CENTRAL FRAME, MOTOR FRONT, BACK PART AND MOTOR
STAND.
STEP-4: THE OBTAIN ASSEMBLE MOTOR IS SHOWN IN THE FIGURE
BELOW

5.2.3. DESIGN OF FRAME:

STEP-1: DRAW A RECTANGLE OF REQUIRED DIMENSIONS USING

PROFILE TOOL BAR AND CONSTRAINT TOOL BAR.

STEP-2: USE PAD COMMAND TO EXTRUDE THE ABOVE SKETCH OF

REQUIRED THICKNESS
STEP-3: USE POCKET COMMAND TO GET A HOLOW SECTIONAL
FRAME

STEP-4: SKETCH A CIRCLE ON THE TOP OF THE FRAME AT REUIRED

POSTION TO OBTAIN THE PULLEY AND SHAFT

STEP-5: THE ENTIRE FRAME IS CREATED AS SHOWN IN FIGURE

5.2.4. DESIGN OF BEARING:

USING SKETCHER TOOL BAR AND ASSEMBLE COMMANDS THE BEARING

AS DRWN AS SHOWN IN THE FIGURE

5.2.5. ASSEMBLY OF COMPONENTS

ASSEMBLE THE ABOVE PARTS AT REQUIRED POSTIONS USING

CONTACT, OFFSET, COINCIDE, AND ANGLE COMMANDS
.
2D LAYOUT OF THE TOTAL DESIGN:
 Chapter - VI
RESULTS AND DISCUSSION
 Chapter - VI
RESULTS AND DISCUSSION

The Theoretical braking time is obtained from the formulas mentioned in the
previous chapter at suitable speeds by taking some assumptions. The experimental
braking time is calculated by taking readings from fabricated model using stop watch
at required speeds. These experimental and theoretical values are compared in this
experiment.

The values of time taken by the wheel to stop when brakes are applied, when
brakes are not applied and also theoretically are shown in the table. And graphs are
plotted for speed of the wheel and theoretical experimental braking time, speed of the
wheel and time taken by the wheel to stop and when brakes are applied , when brakes
are not applied as shown in the graph

The value variation between speed of the wheel and braking time are observed
in XY plane which shows that the time taken by the wheel to stop increases within
increase in speed of the wheel. From the graph it is shown that these brakes are
most effective at high speeds.

Table 6.1: Experimental and Theoretical braking time varying with speed of the
wheel.

Experimental Time taken when

Theoretical
Sl.No. Speed Brakes are not
Brakes are applied Time taken
applied
1. 150 2.10 4.41 0.85
2. 200 2.70 5.13 1.52
3. 250 3.37 5.80 2.38
4. 300 4.34 6.91 3.50
5. 350 5.81 8.26 4.67
6. 400 6.79 8.91 6.10
7. 450 7.95 9.69 7.72
Graphs

12.00

10.00

8.00

6.00
Brakes are Applied
Brakes are Not Applied
4.00

2.00

0.00
0 100 200 300 400 500

5 speed
braking time theoritical
4
braking time experimental
3

0
0 100 200 300 400 500
 CHAPTER-VII
CONCLUSIONS AND FUTURE SCOPE
 CHAPTER-VII
CONCLUSION AND FUTURE SCOPE
7.1 CONCLUSION

Electromagnetic brakes are important supplementary retardation

equipment in addition to the regular friction brakes. They have been used in heavy
vehicles such as coaches, buses, trucks under conditions such as reducing speed in
motorways and trunk roads and braking for prolonged periods during down slope
operations. New types of electromagnetic brakes have been under development for
lighter vehicles as well. Regular friction brakes have an outstanding and vital load
absorbing capability if kept cool. Electromagnetic brakes help friction brakes to retain
this capability under all conditions by absorbing energy at a separate location based
on a totally different working principle.

This report presents the performance of an electromagnetic braking system

which includes various components with its cost effectiveness and efficient
methodologies to utilize the supplied energy. With the application of the effective and
strong electromagnet we can have greater efficient braking system.

The concept designed by us is just a prototype and needs to be

developed more because of the above mentioned disadvantages. These
electromagnetic brakes can be used as an auxiliary braking system along with the
friction braking system to avoid overheating and brake failure. ABS usage can be
neglected by simply using a micro controlled electromagnetic disk brake system
.These find vast applications in heavy vehicles where high heat dissipation is required.
In rail coaches it can used in combination of disc brake to bring the trains moving in
high speed. When these brakes are combined it increases the life of brake and act like
fully